Traction Converter
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TIaction Transformer
Powered Axle
(Motor with wheel)
Train Control
&
Monitoring
Systems (TCMS)
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ISO I4OOI, OHSAS IEOO1 AND ISMS CERTIFIED UNIT
Traction drive systems are extensively used in 1600 HP Broad Gauge AC or Ac/Dc Electrical Multiple Units
(EMUS) and 6000 HP
Phase AC Locomotives
for lndian
Railways. Rapid development in
the field of
semicond uctors and advent of m icroprocessor based controls in traction application have enabled use of Gate
Turn Off Thyristors (GTO's)/lnsu lated Gate Bipolar Transistors (lGBTs) with Squirrel cage lnduction Motors
instead of DC Motors to get better performa nce for a given weight and volume.
the field of Transportation for the last one decade and have been
supplying Vehicle Control Electronics and GTO based Converters for lndian Railways. Today more than 50% of
3 Phase AC Locomotives run with Converters and Controls ma nufactured by BH EL.
BHEL Electronics Division has been in
Advantages of 3 Phase AC Drive Technology
o
3 Phase technology uses GTO Thyristors/lGBTs and Pulse Width Modulation (PWM) techniques on the
Converter as well as the lnverter side with d igital controls for d riving 3 Phase Squirrel Cage lnduction Motor
.3
phase technology has the advantage to work at Unity Power Factor and draws sinusoidal current from
the catenary
Use
of regenerative braking results in energy saving of upto 30%, giving fast payback. This also reduces
wear & tear of bra ke system thereby ensu ring higher life of components
of Squirrel Cage lnduction Motors results in virtually no maintenance as compared to conventional
motors
o Use
DC
System Overview
lncoming power from the catena ry is fed through the transformer to two converters which supply the motive
power through the traction motors. The energy generated d u ring braking is fed back th rough the same cha in
into the traction supply network. lrrespective of motoring or braking, the system continues to supp.ly energy
to the onboard equipments and the vehicle battery.
The overall Traction Control System consists of:
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lnput Transformer
Drive Converter and motor lnverter including
Control Electronics
Auxiliary Converter
Train Control and Monitoring System (TCMS) or
Vehicle Control Unit (VCU)
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Cooling System
Powered Axle (Axle with Motor)
Battery Charger
Drivers screen (Cab Display)
Mechanical Design
Loco Cooling Fans
Compressor
3-Phase AC Motors
Circuit
Main Rectifier
Auxiliary
lnverter
Breaker
Main Translormer
To other 3-phase
AC motors
Block Diagram of Modern Ac Electric Locomotive
Pantograph
3-Phase AC Motors
lnput Transformer
The 25 kV 50 Hz catenary voltage is fed to the primary
winding of the main transformer through pantograph,
main circuit breaker; and a roof cable bushing. The
secondary windings of the main transformer are
connected to GTO/IGBT based front -end converter and
auxiliary converters.
Front End Power Converter and Motor lnverter
The AC power from the secondary winding
of the main
transformer is rectified and regulated by a PWM Converter unit
consisting of IGBT/GTO bridges and then the regulated
DC power is fed to a WVF (Variable Voltage Variable Frequency)
3 Phase PWM inverter u nit. Each inverter feeds either more tha n
one traction motor in parallel (i.e. Bogie control) or single
traction motor (Axle control).
The design of Power Converter is modular type. Currently,
Air-cooled and Oil cooled GTO based power modules are being
used for AC EMU and Loco's respectively. IGBT based air cooled
and water cooled power modules are the futu re technology.
Auxiliary Converter
Auxiliary eq u ipment (Compressors, Blowers for cooling transformers, traction
motors, machine room and scavenger including the battery charger) of the
locomotive/EMU requires 415 V, 3 Phase supply for its operation. This power
is supplied by a set of two/three forced air-cooled IGBT based auxiliary
converters of suitable rating with provision for working either with fixed or
variable frequency. The single-phase supply required for ca bin/locomotive
lighting
is also
supplied from the a uxilia ry converter.
Cooling System
An efficient cooling system is
employed to cool the Power
modules. The GTO based Traction
converters are forced oil-cooled
while the IGBT based traction
Converters are forced water-cooled
Locos. Auxillary convertors are
for
forced air cooled
and AC EMU.
for both
Loco
Train Control and Monitoring System
The Train Control and Monitoring System (TCMS) also known as Vehicle
Control Unit (VCU) is composed of State-of-the-a rt Microprocessor/
Digital signal processors, remote l/O modules and driver display
modules. All these are interconnected by buses and communicate with
each other over a network complying to TCN (lEC 61375) protocol.
TCMS system administers the entire control of locomotive/EMU
operation at different levels (Train, Vehicle and Equipment) over the
network as defined in the Train Communication Network. The important
functions carried out by TCMS are tractive/bra king effort generation, regeneration of power to the
catenary during braking, four quadrant operation, control of all auxiliaries, diagnostic tasks with high
level of reliability, driver display with touch screen facility and automation for ease of operation. ln
add ition to the a bove basic functions, state ofthe a rt slip/slide detection and correction, brake blend ing,
fire protection and multi-loco operation features are a lso being executed byTCMS.
Powered Axle (Axle with Motors)
3 Phase Squirrel Cage lnduction Motors are used for traction
application owing to their ruggedness and low maintenance
features. The motors are axle hung, nose suspended with roller
bea ring a nd forced air cooled/self-ventilated.
Battery Charger
It is a compact forced-ai5ooled, microprocessor controlled unit
with a rated total power df 10KW suitable for operation in high
ambient temperature. Separate outputs for 110V DC loads and
battery are available. The battery charger is designed to perform the
role of charging or DC-DC conversion or a combination of both,
depending on the requirement ofthe system.
Driver's Screen (Cab Display)
The Driver Screen is a PC with colour monitor having touch
screen facility, which provides the following details to the
train driver
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Status information of all equipment of the train
Faults information and Warnings
Trip data and energy consum ption
Control of Passenger information displays etc.
Mechanical Design
All traction equipment viz., Transformer, Motor, Converter/
lnverter, etc. are designed to withstand extremely dusty
atmosphere, high temperatures, humidity and heavy
rainfall. They are also designed to withstand excessive
vibrations that are experienced because of high speed
running and u ndulating terra in.
Emerging Trends in Traction Technology
Availability of high power IGBT's has paved the way for building Traction Converters with IGBT power
modules. Similarly new developments in the area of Microprocessor based Controllers has also
resu lted in en ha nced performance. Some of the sa lient featu res of th is technology are
Power Stacks
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No snubber circuits
Smaller gate circuits
Higher switching frequency
Reliobility ( 30% longer MTBF )
Woter cooled system
lndividual oxle control configuration
Air Cooled IGBT Module
Water Cooled IGBT Module
IGBT
IGBT
Module
Control Philosophy
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Published Open Stondard Platform
Vendor independent
Stondord
RTOS
and third party Softwore tools
Stote-of-the-art Digitol Communicdtion os per
TCN - tEC
61375
Reduction in number of electronic cords
Eose of configurotion and modificotion using
PC bosedtool
Train Bus
Train Bus
Data transmission throughout a train
Control Modules
IGBT based Converter and lnverter for 3 Phase AC EMU
BHEL's Expertise and Capability in Traction
BHEL-EDN has established comprehensive world-class facilities
for its entire range of products,
systems and services. The assembly shops, test laboratories and other manufacturing centers are
well equipped with state-of-the-a rt facilities.
Manufacturing Facilities
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Fabrication shop with state-of-t
e-a rt CNC
machines
Air-conditioned PCB sub-assembly shop with antistatic flooring and a range of automated
component preparation and assembly units, computerised wave soldering machines etc.,
greatly enha nce the ma n ufactu ring
ca pa
bility
Modern Surface Mount Technology (SMT) line with screen printer, pick and place machine,
re-flow oven, inspection station etc., have been established to augment facilities for
ma nufactu ring of electron ic mod
les
with high density
su
rface mou nted com ponents
SMT line for PCB manufacturing
Testing Facilities
Facilities in the PCB test area include computerised testing of components using in-circuit
tester
The main equipment testing section includes world class facilities for functionaltest, short
circuit and temperature rise test. A number of specialised setups are built for functional
testing using simulation concepts
.i.
Device tester for testing of GTOs/lGBTs/Diodes
Comprehensive functional testing facility for modules equipped with test racks, fixtures
and specific test programmes which reduces cycle time fortesting of individual modules
Dedicated test bench for Converter (Traction/Auxilia ry) control rack and Vehicle Control
Electron ics
Environmental chamberforthermal cycling
Testing of Converter/lnverter and Control Electronics
for 3 Phase AC Locomotive
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Testing of6000HP GTO based power converter along with control being performed at BHEL EDN. Each power
module is being tested for full power capacity along with its cooling system. The electronic rack
fu nctiona lly tested with ded icated test jigs.
is
For Jfurlher information please contact
dfwlerr
BHARAT HEAVY ELECTRICALS LIMITED
ELECTRONICS DIVISION
P.B. No. 2606, Mysore Road, Bangalore - 560 026, lNDlA.
Tel: 080-26989042, Fax: 080-26989212. e-mail:
[email protected]Regd. Office: BHEL House, Siri Fort, New Delhi - 110 049.
Visit us at : www.bhel.com / www.bheledn.com
Note : Oue to continuous improvements and changes in technology, BHEL reserves the right to update tho intormation mentioned without notice.
EDN/08/fi/500/85RP
